Transcript
© MHG Heating Ltd
Installation and Operating Manual for the ProCon MC 115 Wall Mounted Condensing Boilers
1 MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email
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© MHG Heating Ltd Section
Page
Appliance Type
3
ProCon MC
3
Installation Regulations and Requirements
4
Appliance Warranties Supplied Components
5
Dimensions
6
Installation Clearances and Mounting Information
8
Delivery and Mobility
9
Case Removal
9
Hanging The Boiler
9
Technical Data
10
Pressure Relief Valve
12
Electrical Connections
13
Internal Wiring Diagram
14
BMS Clip MCBMSADAPT (AM3)
16
0-10 Control Clip MC0-10ADAPT (AM4)
17
Hydraulic and Wiring Guide Single Unit Option 1 (Heating Only
18
Single Boiler Hydraulic Kit
19
Hydraulic and Wiring Guide Single Unit Option 2 (Heating & HWS)
21
Hydraulic and Wiring Guide Twin Boiler Option 3 (Cascade System Heating & HWS)
22
Two Boiler Cascade Option 1
23
Two Boiler Cascade Option 2
24
Three Boiler Cascade Option 1
25
Three Boiler Cascade Option 2
26
Four Boiler Cascade Option 1
27
Four Boiler Cascade Option 2
28
Erection of Boiler Cascade Frame Option 1
29
Erection of Boiler Cascade Frame Option 2
30
Cascaded Open Flue Non Return Valve Options
33
Cascaded Open Flue Options 1 & 2
34
Cascaded Hydraulic Transition / Safety Section (Temperature and Pressure Monitoring)
37
Theta Cascade Manager Housing, Wiring, Clip Installation, Clip Configuration
37
Theta Electrical Connections
38
Fluing Options
44
Single Unit Balanced Flue Wall Termination DN160/110
45
Single Unit Balanced Flue Vertical Termination DN160/110
45
Single Unit Balanced Flue with Twin DN125 Products of Combustion and Combustion Air Ducts
46
Single Unit Open Flue Wall Termination DN125
46
Single Unit Open Flue Vertical Termination DN125
46
Dimensions of Available Flue Components
47
Balanced Flue Terminal Positions For Boilers below and Above 70kW Net Input
49
Filling The System
50
Pressure Vessel
51
System Water Quality
51
Care With The Use Of Solder Flux
52
Appliance Controls
53
Module Operating Codes
56
Temperature Display
56
Fan Speed Display
57
Last Error Code Display
57
Appliance Fault Codes
58
Cut-Out Codes
60
Weather Compensation Curve
61
Boost Function
62
0-10 Volt Control Adjustment
63
NG/LPG – LPG/NG Conversion Procedure
64
Commissioning The Appliance
65
Pre-Commissioning Checks
65
Combustion System Commissioning
66
Routine Inspection and Servicing
68
User Information
71
Operating Modes
72
Cut-Out Codes
73
Setting the Operating Temperatures
74
Operational Diagram
75
Sensor Resistance Tables
76
Exploded Spares Diagram
77
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© MHG Heating Ltd Appliance Type There is currently only a single boiler in the ProCon MC range. Additional boilers are being designed and will be available shortly. ProCon MC 115 The ProCon MC 115 is designed to be applied to systems requiring direct on boiler weather compensated heating and priority hot water production via a separate high recovery calorifier/cylinder. The ProCon MC 115 can be applied to a cascade of up to seven boilers using a MHG Theta cascade manager, however, the current range of mounting frames only accommodate a maximum of four boilers with matched hydraulic and flue sets. Dedicated cascade controllers, communication adapters, mounting frames, hydraulic kits and flue kits are available if required.
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© MHG Heating Ltd Installation Regulations and Requirements The installation of ProCon MC boilers must be in accordance with the relevant requirements of Gas Safety (Installation & Use) Regulations 1994, Health & Safety at Work Act, Building Regulations, IEE Regulations, Construction (Design & Management) Regulations 1994, Local Authority Bye-Laws, National, Fire Regulations and Insurance Company requirements. The following Codes of Practice are also applicable:BS 5440-1: 2008 Installation of flues and ventilation for gas appliances of rated input not exceeding 70 kW net (1st, 2nd and 3rd family gases). Part 1: Specification for the installation of flues. BS 5440-2: 2009 Installation of flues and ventilation for gas appliances of rated input not exceeding 70 kW net (1st, 2nd and 3rd family gases). Part 2: Specification for installation and maintenance of ventilation for gas appliances. BS 5449: 1990 Specification for forced circulation hot water central heating systems for domestic premises. BS 6644: 2011 Specification for gas fired hot water boilers of rated inputs between 70kW (net) and 1.8MW(net) (2nd and 3rd family gases). BS 6798: 1987
Specification for installation of gas fired hot water boilers of rated input not
exceeding 60 kW. BS 6880: 1988 Code of Practice for low temperature hot water heating systems of output greater than 45kW. Parts 1, 2 & 3. BS 6891: 1988 Specification for installation of low pressure gas pipework of up to 28mm (R1) in domestic premises (2nd family gases) BS 7593: 1992
Code of Practice for treatment of water in domestic hot water central heating
systems. BS 7671: 1992 Requirements for electrical installations. IEE Wiring Regulations. Sixteenth edition. CISBE Guide reference sections B7, B11 and B13. CP342 Part 2: 1974 Code of Practice for centralized hot water supply. GE/UP/2
Gas installation pipework, boosters and compressors on industrial and commercial
premises. IGE/UP/4 Commissioning of gas fired plant on industrial and commercial premises IGE/UP/10
Installation of gas appliances in industrial and commercial premises. Part 1: Flued
appliances. And any addition prevailing regulation and or code of practice not detailed above.
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© MHG Heating Ltd Appliance Warranties All MHG appliances enjoy a full 24 month warranty as detailed in our terms and conditions. The guarantee period shall begin on the day of commissioning, or within 3 months after delivery has been made. The customer shall only be able to claim against MHG under guarantee if the commissioning of the object of delivery has been carried out by MHG staff or the authorized supplier. Only if the customer has followed MHG's instructions relating to the treatment and maintenance of the object of delivery, and if no replacement parts of outside origin have been fitted. Parts subject to wear such as ignition electrodes, seals etc. are strictly excluded from the guarantee. In addition to the above warranties, the Primary Heat Exchangers carry a 60 month guarantee against manufacturing or material defect. Supplied Components All ProCon 115s are supplied with the following components: Pressure relief valve outlet extension, seal and Tundish.
A DN100-125 flue adapter to provide a flue gas analysis sampling point and a combustion air inlet adapter and seal. (The adapter may be omitted depending upon the proposed flue route.)
Six screws for securing the rear panel to the boiler prior to fixing the boiler to the wall or frame.
Two Case Entry Sealing Grommets.
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© MHG Heating Ltd Dimensions
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© MHG Heating Ltd
Legend MI
System Flow 1.25” BSP M
VS
Pressure Relief Valve Discharge 0.75” BSP F
GAS
Gas Inlet 0.75” BSP M
RI
System Return 1.25” BSP M
SC
Condensate Drain 25mm
VE
Pressure Vessel Connection
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© MHG Heating Ltd Installation and Service Clearances
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© MHG Heating Ltd
Delivery and Mobility All ProCon MCs are supplied fully tested and therefore may contain residual test water. The test water utilised contains additives that will help prevent the pump from sticking and other metals from oxidising. To maintain the structural integrity of the appliance the internal components should not be used during the lifting and positioning of the unit onto the customer supplied wall fixings. All packaging materials should be disposed of in an environmentally way. Case Removal The lower case covering the display can be hinged down to gain access to the control panel facia. The facia can also be hinged down following the disengaging of the retaining screws by turning through 90 degrees. The upper front case panel can be removed by firstly removing the two top panel securing screws then slide the panel up and pull forward. Hanging the Boiler. Due to the varied nature of the wall mounting locations/conditions that can be encountered a wall mounting bracket is not supplied with the ProCon MC115. Mounting frames for use with one to four boilers are available. Free standing or supported versions are available.
Mounting holes are located at the top rear of the boiler. It is advisable to use raised shoulder/head fixings or adequately secured studding in combination with square washer and securing nuts to aid location and mounting. If the boiler is to be raised in to position on a mechanical lifting device, it is essential that the base of the unit and the components immediate inside are protected from damage by using bracing timbers located as shown in the image to the right.
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© MHG Heating Ltd
Technical Data General Boiler Data
115 kW
Type of fume discharge Category
ll2H3+ Natural gas
Fuel type
/PLG Min
Max
Nominal heating capacity
kW
27.0
108.0
Reduced-nominal thermal power (50/30°C)
kW
29.7
115.0
Reduced-nominal thermal power (80/60°C)
kW
25.9
105.0
Energy output (Dir. 92/42/EEC-Law 10/91-LD 192) Usable thermal output at nominal power (80/60°C)
%
97.5
Usable thermal output at 30% nominal power (50/30°C)
%
108.3
Usable thermal output at nominal power (50/30°C)
%
106.7
Energy output (Dir. 92/42/EEC)
%
****
Loss to shell (Dt=50°C) Pd
%
0.2
Loss to fumes with burner on Pf
%
Loss to fumes with burner off Pfbs
%
2.3 0.1 0.8
Chimney size Fume temperature (80/60°C)
°C
53
72
Fume temperature (50/30°C)
°C
31
CO2 value
%
8.9
52 9.1
Residual channel head from smoke (without clapet valve)
Pa
20
90
Maximum gas capacity at min/max nominal power
kW
45.8
179.3
Diam. Of fume discharge
mm
100
Diam. Of discharge stub with smoke exhaust
mm
125
Combustion/gas data Gas capacity at nominal power 1)G20
m3/h
2.86
Gas capacity at nominal power 1)G30
kg/h
2.13
Gas capacity at nominal power 1)G31
kg/h
2.18
11.43 8.52 8.39
NOx Class (according to EN 483 – EN 656)
5
Dynamic gas pressure on inlet – Natural Gas G20
mbar
20
Dynamic gas pressure on inlet – Natural Gas G30/31
mbar
28-29/37
Gas connector
inches
G1M
(Screened cable must be used for all low voltage and sensor wiring)
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© MHG Heating Ltd
Hydraulic data Water content of individual heating element
L
10.60
Heating circuit water content
L
11.20
Maximum working pressure
bar
Diam. of return system
inches
Diam. of fume discharge coupling
mm
Load loss on water input side (Dt=20°C)
mbar
Maximum quantity of condensation (50/30°C) (CH4)
l/h
4.0 G1¼ 25.0 See curve 17.0
Dimensional data Overall dimension (HxLxD) Weight
mm
900x600x620
kg
90
Electrical data Power supply
VAC/Hz
230/50
Total absorbed power
W
469
Maximum power on standby
W
50
Load Loss on Water Input Side Curve (DT=20C)
Designed flow rate at max output 4.95 m3/h
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© MHG Heating Ltd Pressure (Safety) Relief Valve In accordance with the prevailing British Standard 5440/6644, the installer shall install as suitably sized Pressure (Safety) Relief Valve. The location of this valve is important with respect to the applied pressure of the boiler circulation pump, it is therefore recommended to locate the Pressure (Safety) Relief Valve on the flow pipe immediately adjacent to the boiler; furthermore, there must not be any means of isolation between the boiler and the Pressure (Safety) Relief Valve. A pressure Relief Valve has been supplied within the unit. Standard setting: 3.4bar
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© MHG Heating Ltd Electrical Connections Basic electrical connection for the ProCon MC
Legend 230 Volts 1
Power Supply Plug
230 Volts. 5 Amp. Live, Neutral, Earth.
X20
24 Volts 2 3 4 5
Cascade Adapter Plug
Interfacing Plug for use with a Dedicated Theta Cascade Controller
Enabling/Safety
Volt Free Enable T7 & T8
Plug
Safety Interlocks (For use with installation kit) T7, T6 & B5
Outside Air Sensor Plug Hot Water Sensor Plug
X22 X21
Outside air sensor if Direct On Boiler Weather Compensation is required.
SE
Sensor or Volt Free Enable Plug.
T3
(Screened usedfor when voltvoltage free enable required) (Screenedcable cablemust must be be used all low and sensor wiring)
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© MHG Heating Ltd Internal
Wiring
Diagram
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© MHG Heating Ltd
Key CI
–System circulating pump (230V AC)
EI
–Summer / off / Winter switch
VD -Bypass valve actuator (24V AC) (Optional depending on the version)
EVG –Gas solenoid Valve (24V AC)
X1
-Board-circulating pump thermal board
F1
-F 2A / 250V fuse (230V supply)
X2
-Thermostat valve fan connector
F2
-F 2A / 250V fuse (24V circuit)
X3
-Probe connector
F3
-T 3A / 250V fuse (24V electric fan)
X5
-Detection Electrode
H1
-Powered boiler warning light (24V AC)
X7
-Service connector (optional)
H2
-Flame lit warning light (24V AC)
X8
-Control board connector
HV
-Ignition electrode
X10 -Thermostat pressure switch common terminal
IC
-Communication interface (optional)
X11 -Auxiliary terminal board
MV
-Fan motor (24V DC and 230V AC)
X13 -Bypass valve terminal
PDA -Differential water pressure switch
X14 -Bypass valve microswitch terminal
PmA -Min. water pressure switch
X17 -Common probe terminal
PS
-Safety pressure switch
X18 -Boiler temperature probe terminal
SE
-External probe (optional)
X19 -External probe terminal
T1
-Boiler delivery temperature probe
X20 -Supply connector
T2
-Boiler return temperature probe
X21 -ISPESL safety connector
T3
-Boiler temperature probe (optional)
X22 -Heating unit management connector
TA
-Room thermostat (optional)
X30 -BUS connector (optional)
TRS -Safety and adjustment thermostat TSF -Fume safety thermostat / thermofuse
Z1
-Anti interference filter
BK-Black/RD-Red/WH-White/BU-Blue/BN-Brown
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© MHG Heating Ltd Installing a MCBMSADAPT (AM3) BMS Adapter (Volt Free Fault and Run indication) This must be used if: A Run or Fault output is required from the ProCon MC boiler -Remove the cover from the dashboard
-Fasten the interface with the screws supplied
-Connect the interface board to the boiler control board (MCBA) Using the flat wire provided. -Position the flat wire so that it is not compressed when the closing cover is placed on the dashboard
-X1 1&2 Fault indication relay. Normally open, closes on fault
-X2 1&2 Run indication relay. Normally open, closes on run
(Screened cable must be used for all low voltage and sensor wiring)
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© MHG Heating Ltd Installing a MC0-10ADAPT (AM4 0-10V) Adapter This must be used if: 0-10 Volt control of the boiler from building management system is required -Remove the cover from the dashboard
-Fasten the interface with the screws supplied
-Connect the interface board to the boiler control board (MCBA) Using the flat wire provided. -Position the flat wire so that it is not compressed when the closing cover is placed on the dashboard
-Connect the 0-10V signal wire on connector X2, taking care to respect the polarity: terminal X2-1 signal +10V; terminal X2-2 signal 0V. X1
–Alarm relay. This contact is closed as soon as there is a a
a
boiler block.
X2 1-2
-Analogue input 0-10V (X2-1=Input+, X2-2=0V).
a
speed or the delivery temperature (type of function settable a
a
via parameter 45)
X2 3-4
-Do not use
X2 5-6
-Do not use
X7
-Collection of flat communication wire
The voltage is directly proportional to the fans rotation
(Screened cable must be used for all low voltage and sensor wiring)
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© MHG Heating Ltd Hydraulic Design Single Unit (Option 1)
If a HWS Volt Free Enable is used in place of a sensor Parameter 46 will require updating from 22 to 21 (Screened cable must be used for all low voltage and sensor wiring)
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© MHG Heating Ltd Single Boiler Hydraulic kits are also available
Legend 1
ProCon MC115
10
Air Separator
2
Test Thermostat Pocket
11
3 Way Vent Valve
3
Limit Thermostat
12
Low Loos Header With AAV
4
SSOV Pocket
13
Return Service Valve
5
Pressure Testing 3 Way Valve
14
Strainer Y
6
Pressure Gauge
15
Filter
7
Maximum Pressure Switch
16
SSOV Actuator
8
Minimum Pressure Switch
18
Pressure Vessel
9
Thermometer
All parts are available in kit form 19
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© MHG Heating Ltd Kit Formation
Legend 1
ProCon MC115
10
Air Separator
2
Test Thermostat Pocket
11
3 Way Vent Valve
3
Limit Thermostat
12
Low Loos Header With AAV
4
SSOV Pocket
13
Return Service Valve
5
Pressure Testing 3 Way Valve
14
Strainer Y
6
Pressure Gauge
15
Filter
7
Maximum Pressure Switch
16
SSOV Actuator
8
Minimum Pressure Switch
18
Pressure Vessel
9
Thermometer
All parts are available in kit form
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© MHG Heating Ltd Hydraulic Design Single Unit (Option 2)
If a HWS Volt Free Enable is used in place of a sensor Parameter 46 will require updating from 22 to 21 (Screened cable must be used for all low voltage and sensor wiring)
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© MHG Heating Ltd Hydraulic Design Twin Boiler (Option 3 )( With Optional Theta Cascade Controller)
Please refer to the Theta Cascade Manager section later in this manual for wiring guidance. If a Theta control is to be used the boilers require cascade clips. White wire/plugs will be present within the boilers case.
Independent Volt Free Enables must be provided if the boilers are not being controlled by a Theta Cascade Manager.
If a HWS Volt Free Enable is used in place of a sensor Parameter 46 will require updating from 22 to 21 (Screened cable must be used for all low voltage and sensor wiring)
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© MHG Heating Ltd Cascade Options Prefabricated cascade kits are available if required. (PN6 Flanges) Two Boiler Cascade: Option 1 (Requiring a wall or suitable structure for support)
115+115 A
2335
B
620
C
214
D
115
E
115
F
285
G
550
H
55
I
DN160
J
625
K
352
L
276
M
677
N
280*
O
420
P
902.5
Q
692.5
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© MHG Heating Ltd
Two Boiler: Option 2 (Not requiring a wall or suitable structure for support)
115+115 A
2150
B
1300
C
350
F
320
G
615
H
360
I
DN160
J
685
K
352
L
276
M
677
N
280*
O
420
P
885
Q
675
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© MHG Heating Ltd
Three Boiler Cascade: Option 1 (Requiring a wall or suitable structure for support)
115+115+115 A
2375
B
620
C
214
D
155
E
155
F
285
G
550
H
55
I
DN200
J
705
K
352
L
276
M
677
N
280*
O
420
P
902.5
Q
692.5
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© MHG Heating Ltd Three Boiler Cascade: Option 2 (Not requiring a wall or suitable structure for support)
115+115+115 A
2425
B C
1300 350
F
320
G
615
H
780
I
DB200
J
765
K
352
L
276
M
677
N
280*
O
420
P
685
Q
675
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© MHG Heating Ltd Four Boiler Cascade: Option 1 (Requiring a wall or suitable structure for support)
115+115+115+115 A
2450
B
620
C
214
D
115
E
115
F
285
G
550
H
35
I
DN200
J
725
K
352
L
276
M
677
N
280*
O
420
P
902.5
Q
692.5
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© MHG Heating Ltd Four Boiler Cascade: Option 2 (Not requiring a wall or suitable structure for support)
115+115+115+115 A
2475
B C
1300 350
F
320
G
615
H
780
I
DB200
J
765
K
352
L
276
M
677
N
280*
O
420
P
685
Q
675
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© MHG Heating Ltd Erection Procedure of a Boiler Cascade Frame: Option 1 (Requiring a wall or suitable structure for support)
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© MHG Heating Ltd Erection Procedure of a Boiler Cascade Frame: Option 2 (Not requiring a wall or suitable structure for support)
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© MHG Heating Ltd
(PN6 Flanges)
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© MHG Heating Ltd The 3 way vent valves will need to be configured to ensure correct operation. This is achieved by realigning the handle and the valve insert. As detailed below.
Please ensure that the 3 way vent valve are mounted with the handle pointing forward and the vent outlet pointing to the right. This will ensure that the supplied drain hoses fit!
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© MHG Heating Ltd Cascaded Appliance Fluing Installation Open Flued A full range of cascade flue items can be supplied by MHG. If alternative suppliers are used it is essential that an approved non return valve is used to prevent recirculation of products of combustion through non firing boilers. Non Return Assembly.
*A flue spigot adapter is also required*.
Please refer to the cascade options detailed earlier in the manual.
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© MHG Heating Ltd Cascaded Open Flue Options 1 & 2
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© MHG Heating Ltd
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© MHG Heating Ltd
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© MHG Heating Ltd Optional Hydraulic Cascade Transition / Safety Section (Temperature and Pressure Monitoring)
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© MHG Heating Ltd Theta Wiring Data Prefabricated Cascade Wiring (Black & Green Plugs / System Safety Interlocks)
X 20 Black Plugs & X 22 Green Plugs Ensure that the boilers are connected to the correct plug output. The closest boiler to the cascade controller being #1 X 21 can be wired to the hydraulic kit system safety devices if applied. (See above: Hydraulic Cascade Transition / Safety Section. (Temperature and Pressure Monitoring.)) Alternatively they can be connected to a MHG System Pressure Managers high and low pressure switches or simply linked out if no external pressure or temperature monitoring is required.
(Screened cable must be used for all low voltage and sensor wiring)
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© MHG Heating Ltd Prefabricated Cascade Wiring (White Plugs)
X30 White Plugs Ensure that the boilers are connected in series to the preformed white cascade cables.
Sensor and System Component Wiring To ensure the correct operation of the Theta controller a common flow sensor must be connected. Plug #
Terminals
Function
Voltage
Max Amps
Sensors X15.1
L1 - E
Common Flow Senor
<24V
NA
X15.1
L1 - N
HWS Sensor or Volt Free Enable
<24V
NA
X15.2
L1 - N
Mixed Heating Zone 1 Flow Sensor
<24V
NA
X15.2
L1 - E
Mixed Heating Zone 2 Flow Sensor
<24V
NA
X31
L1 - E
Outside Air Sensor
<24V
NA
Pump and Valve Outputs X23
L1 – N - E
Main Heating Circuit Pump
230V
2 Amp
X23.1
L1 – N - E
Mixed Heating Zone 1 Pump
230V
2 Amp
X23.2
L1 – N - E
Mixed Heating Zone 2 Pump
230V
2 Amp
X24
L1 – N - E
HWS Charging Pump
230V
2 Amp
X26.1
L1 – E - N
Mixed Heating Zone 1 Valve
(L1 = Open E = Close)
230V
1 Amp
X26.2
L1 – E - N
Mixed Heating Zone 2 Valve
(L1 = Open E = Close)
230V
1 Amp
(Screened cable must be used for all low voltage and sensor wiring) MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email
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39
© MHG Heating Ltd Installation of the cascade Communication Clips RMCI 1400 EBV3 SU
Remove Control panel rear cover
Install Clip In location as Indicated
Install Ribbon Cable to X7
Install the piggy back equipped wires as shown to the L & N Terminal
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© MHG Heating Ltd
Install the White plug Connection Cables to Terminals Brown Wire A & White Wire B and the appliances Earth. Leave the white plugs within the appliances case ready for connection to the Theta controller cascade wiring.
Cascade Clip Configuration
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© MHG Heating Ltd Theta Cascade Manager The Theta Cascade Manager can be used to control up to Eight ProCon MC 115s. The unit is supplied in a dedicated housing and associated sensors. Each ProCon will require a Cascade Communication Clip. The Theta Cascade Controller can proved direct control of: Up to Eight ProCon MC 115. One Direct Heating Zone. (With Optional Room Unit. With or Without Direct on Boiler Compensation.) Two Variable Temperate (3 Way Mixing Valve) Zones. (With Optional Room Unit. With or Without Compensation.) Direct Hot Water Generation. Thermal Solar Input to Domestic Hot Water Generation. 0-10 Volt Drive response. Remote monitoring and adjustmet via The Internet (LAN) or Mobile Network (GSM)
Please refer to the separate Theta Controller manual for guidance on parameter settings. A copy is supplied with the unit, it is availible from the website or from MHG’s Technical Department.
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© MHG Heating Ltd Theta Electrical Connections
Legend #
Terminals
A1
~
Plug
Description
CB
5/N
X 24
CBT1 / CBT2
9 / 15
X 23.1.2
Mixing Zone Pumps
CI
3/N
X 23
System Heating Pump
Theta Controller HWS Primary Pump
CMI
37 / 38 / N
ProCon MC115 Cascade Interface Clip
CSOL
11 / N
Solar Pump
SE
26 / 23
X 31
T3
27 / 23
X 15.1
Common Flow Sensor
T4
28 / 23
X 15.1
HWS Sensor / Volt Free Enable
T5
29 / 23
X 15.2
Mixing Circuit 1 Sensor
T6
33 / 23
X 15.2
Mixing Circuit 2 Sensor
T7
34 / 23
Solar Collector Sensor
T8
35 / 23
Solar Buffer Sensor
VM1 / VM2
7 / 8 / 13/ 14 / N
Outside Air Sensor
X 26.1.2
Mixing Circuit Mixing Valves
X1
~
Low Voltage Connections
X2
21 / 22
230 Volt Input Connections
X3
~
230 Volt Output Connections
X4
~
230 Volt Output Connections
1-10 V
24 / 25
0 – 10 Volt Interface Module
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© MHG Heating Ltd Fluing Options Please note that excessive resistance within the flue and combustion air supply systems will lead to a reduction in the output of the appliance and induce operational faults. DN110/160 Concentric Flue Components (Pa Resistances) Concentric Adapter
TBC
Wall Terminal
TBC
Vertical Terminal
TBC
955mm Flue Extension
TBC
500mm Flue Extension
TBC
255mm Flue Extension
TBC
87º Bend
TBC
45º Bend
TBC
30º Bend
TBC
DN125 PPS Flue Components (Pa Resistances) Exhaust Pipe Terminal
TBC
Air Pipe Terminal
TBC
955mm Flue Extension
TBC
500mm Flue Extension
TBC
255mm Flue Extension
TBC
87º Bend
TBC
45º Bend
TBC
30º Bend
TBC
When flues are installed with horizontal sections/portions a 30 fall back to the boiler must be maintained. This will not only ensure condensate removal preventing premature seal failure, but also prevent nuisance condensate dripping from the wall terminal.
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© MHG Heating Ltd Single ProCon Balanced Flued Through The Wall Termination (DN 110/160)
Single ProCon Balanced Flued Vertical Termination (DN110/160)
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© MHG Heating Ltd
Single ProCon Individually Routed Combustion air and Products of Combustion Individual DN125 solid or flexible flues can be utilized with the ProCon range
Single ProCon Open Flued Through The Wall Termination (DN 125)
Single ProCon Open Flued. Vertical Termination. (DN125)
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© MHG Heating Ltd Dimensions of Available Concentric Flue Components Description
Image
Concentric Adapter DN110/160
Concentric 87° Elbow DN110/160 with Control Opening
Concentric Straight DN110/160 with Control Opening
Concentric 30° Elbow DN110/160
Concentric 45° Elbow DN110/160
Concentric 87° Elbow DN110/160
Concentric 225mm Straight DN110/160
Concentric 500mm Straight DN110/160
Concentric 955mm Straight DN110/160
Concentric 225mm Straight with Condensate Syphon DN110/160
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© MHG Heating Ltd
Concentric Wall Terminal 1000mm DN110/160
Concentric 1450mm Roof Terminal DN110/160
Flat Roof Flashing
Pitched Roof Flashing
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© MHG Heating Ltd Balanced Flue Terminal Positions For Boilers Below and Above 70kW Net Input (All measurements are in mm and are minimum clearances)
Boilers with a rated Input < 70kW Net
Boilers with a rated Input > 70kW Net
A
*Below and opening window etc.
Terminal Location
300
600
B
Below gutter soil pipes etc.
75
700
C
Below Eaves.
200
200
D
*Below balconies or car port roof.
200
N/A
E
From vertical drain or soil pipe etc.
150
150
F
From internal or external corners.
300
300
G
Above ground or balcony level.
300
H
From a surface facing the terminal.
2000
2000
I
From a terminal facing the terminal.
2000
2000
1200
N/A
1500
1500
300
600
500
600
300
600
500
500
500
500
J K L M N P Q
*From opening in a carport into a dwelling. Vertically from a terminal on the same wall. Horizontally from a terminal on the same wall. Above an opening, window etc. *Horizontally to an opening, window etc. Above a level roof (base of terminal.) From an adjacent wall (edge of terminal.)
300 (2000 where people have general access)
R
From adjacent opening, window etc.
1000
1000
S
From any other flue terminal.
600
600
* Positions not recommended
Groups of appliances of 150kW gross input (136kW net input) and above must comply with the Clean Air Act with respect to the chimney discharge height. The terminal/s shall be guarded if it is less than 2000mm above the ground or in any position where it may cause injury to persons resulting from touching a hot surface. Absolute guidance must be sought from the respective regulation.
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© MHG Heating Ltd Filling The System The Initial filling of a sealed heating system, and subsequent refilling, must be by a method that has been approved by the Water Regulation Advisory Scheme (WRAS) for that type of heating system. i.e.
Domestic (In-House)
Fluid Category 3 (C-3)
Non Domestic (Other than In-House)
Fluid Category 4 (C-4)
For Category 3 systems, the approved method of filling must comprise of the following components in the arrangement shown;
Control Valve incorporating a Double Check Valve on the Mains Cold Water pipework.
Temporary Connecting Hose, which must be disconnected after use.
Control Valve, on the heating system.
For Category 4 systems, the approved method of filling must comprise of the following components in the arrangement shown;
Control Valve.
Strainer.
Verifiable Backflow Device with Reduced Pressure Zone (RPZ Valve).
Incorporating a ‘Type BA’ Air Gap.
Tundish.
Control Valve.
Furthermore, in accordance with BS 6644: 2011 system with an input greater than 70kW (nett), an automatic water replenishment unit shall be installed to automatically replenish any lost or evaporated water. Please refer to BS 6644: 2011 for allowable water replenishment methods for use with sealed/pressurized heating systems.
For information on a comprehensive range of pressurization units that comply with current British Standards and WRAS Regulations, please contact MHG Heating Ltd Sales.
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© MHG Heating Ltd Expansion Vessel In accordance with BS 6644: 2011, WRAS Regulations, and Local Authority Water Regulations, as applicable, the installer shall install a suitably sized, and approved, Expansion Vessel to ensure that the water capacity of the system has ample expansion capacity. In complete compliance with BS6644:2011 a tapping is provided at the base of the boiler for the connection if a dedicated expansion vessel. The location of the expansion vessel shall only be isolatable from the system via a Lockable Type Service Valve, which shall be locked in the OPEN position, to prevent accidental isolation. Furthermore, a drain facility should be provided adjacent to the expansion vessel to aid the routine maintenance, overhaul, of the vessels Air Pressure setting.
For information on a comprehensive range of expansion vessels that comply with current British Standards and WRAS Regulations, please contact MHG Heating Ltd Sales. System Water Quality Cleaning, flushing and water treatment must be carried out in accordance with the requirements of prevailing Building Regulations, British Standards, CIBSE Guides and related documents. The entire system/s MUST be thoroughly cleaned and flushed to remove debris, flux residues, etc. before opening the boiler isolation valves & flooding the boiler. Particular care must be taken where the ProCon boiler is being retro-fitted into an old/existing system, as system silt or magnetite can be very damaging to the new boiler. Consideration must be given to the installation of a MHG matched plate heat exchanger. Failing this a suitable straining/filtering device must be utilized to remove water borne debris.
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© MHG Heating Ltd Following the cleansing and flushing the system MUST be dosed with a good quality water treatment to prevent corrosion and the formation of scale. FAILURE TO OBSERVE THESE REQUIREMENTS WILL RENDER THE WARRANTEE ON THE APPLIANCE VOID. Repeated draining planned or via leaks and refilling of the system, without replenishment of water treatment, must be avoided, as this is very damaging to the boiler and system components. Before activating the boiler following the initial installation or hydraulic remedial work on the system, allow the system to circulate for at least 2 hours with the boiler off. This will allow the system installed devices to capture/remove any water borne debris. (Micro Air Bubble & Impurity separators). These devices must then be cleaned prior to commissioning the boiler. Additional device cleaning may be required during the first heating cycles. The system water must have the following characteristics to ensure the long term operation security of all boiler and system components.
For specific guidance on water treatment, direct contact is advisable with:Betz Dearborn Limited
Alpha-Fry Technologies (Fernox)
(Sentiel)
Cookson Electronics
Foundry Lane
Forsyth Road
Widnes
Woking
Cheshire
Surrey
WA8 8UD
GU21 5RZ
Tel: 0151 424 5351
Tel: 0208 665 6666
Care With The Use of Solder Flux The ProCon MC range has heat exchangers fabricated from 304L Stainless Steel.
It is most
important that the compatibility of any flux is checked with the supplier before use, and that any flux manufactures recommendations are strictly followed with regards to use in conjunction with Stainless Steel. If you are applying any of the ProCon Range to a system where the water quality cannot be cleansed or treated please consider installing a system separation plate heat exchanger to ensure absolute separation of the system water and the boiler water. Please refer to our website for further details on our matched brazed and gasketed plate heat exchanger range.
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© MHG Heating Ltd Appliance Controls All appliance operational mode adjustments and settings are undertaken via the unit control fascia.
Button
Function
COD
LED Display. Operating Temperature, Modes and Fault Codes
RESET
Resetting of an Operation Fault
MODE
Selections of an Operating Mode to Inspect or Amend
STEP
Scrolling of the Parameter List
STORE
Saving any Parameter Alterations
+
Positive Adjustment
-
Negative Adjustment
The controller can provide the following levels of information and adjustment. System Configuration Control Configuration Weather Compensation Configuration Temperature Configuration Speed Configuration Pump Configuration Historical Error Code Recovery To prevent functional parameters from being altered in error they are located behind a code. To access this level the following procedure must be followed: Press the MODE and STEP buttons simultaneously until the display indicates
CODE
Press the STEP button once. The display indicates
C. ??
Press the + or – buttons to change the third and fourth digit to 54
C. 54
Press the STORE button and the display will blink for a few seconds to indicate that the code has been accepted.
C. 54
Press the MODE button until the desired menu is displayed a DOT will be
Standby, Para,
seen in the bottom right of the first digit box.
Info, ect.
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© MHG Heating Ltd
Display
Description of parameters
Factory setting
1
Hot Water set point. T3
50
Suggested Changes 60
Setting DHW on or off; 2
00 = off
02 = off + pump on continuous
01 = on
03 = on + pump on continuous
00
Setting CH on or off; 3
4 P.10
00 = off
02 = off + pump on continuous
01 = on
03 = on + pump on continuous
01
Maximum set point in Heating mode.
60
(at minimum outside temp) Minimum set point in Hating mode.
20
(at maximum outside temperature)
P.11
Minimum outside temperature of Heating curve.
-20
P.12
Maximum outside temperature of Heating curve.
25
P.13
Frost protection start temperature
-10
P.14
Correction of outside temperature
00
P.15
Maximum set point for 2nd Heating circuit
20
P.16 P.17 P.18
Minimum set point for
2nd
Heating circuit
T6
110°C
“RESET”, replace the MCBA unit -Check the NTC wire and replace if necessary -If the NTC1 probe is OK, make sure water is circulating.
E.19
T2>110°C
-Check the NTC wire, replace if necessary
E.24
NTC probe error
Inversion of NTC1 and NTC2
E.25
Delivery temperature T1 rising to quickly
-Check the pump operation -If the pump is ok, purge the system -Check the PWM connection
E.28
-Check the fan wiring
No signal from tachometer
-If the problem persists after two attempts to “RESET”, replace the MCBA unit
E.29
The tachometer signal of the fan does not
-Check extraction of the flue
return to “0”
-If extraction is correct replace the fan
E.30
NTC probe safety
-Exceeded the max ∆T
E.31
NTC short circuit
-Check the NTC1 probe connector -Check the NTC1 probe wiring -If the problem persists replace the NTC1 probe -Check the NTC2 probe connector E.32
NTC2 short circuit
-Check the NTC2 probe wiring -If the problem persists replace the NTC2 probe
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© MHG Heating Ltd
Codes
Error Description
Error Resolution -Check the NTC3 probe connector
E.33
NTC3 short circuit
-Check the NTC3 probe wiring -If the problem persists replace the NTC3 probe -Check the NTC1 probe connector
E.36
NTC1 connection open
-Check the NTC1 probe wiring -If the problem persists replace the NTC1 probe -Check the NTC2 probe connector
E.37
NTC2 connection open
-Check the NTC2 probe wiring -If the problem persists replace the NTC2 probe -Check the NTC3 probe connector
E.38
NTC3 connection open
-Check the NTC3 probe wiring -If the problem persists replace the NTC3 probe
E.44
Internal error
E.60
Error during reading
E.65
Fan power supply problems
-If the problem persists after two attempts to “RESET”, replace the MCBA unit -Perform a RESET -If the error persists, replace the MCBA unit -Check the power supply voltage of the MCBA -If no problem is found, replace the fan
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© MHG Heating Ltd Cut-Out Codes If the boiler has malfunctioned an error/cut-out code will be displayed in the first, third and fourth segments.
Status
Boiler Operation
b.08
Air pressure switch
b.18
Delivery temperature T1>95°C
b.19
Return temperature T2>95°C
b.24
T2-T1 > 10°C after 90 seconds
b.25
dT1 / dt > maximum gradient T1
b.26
Gas pressure switch or absence of water not closed / Thermostat for regulation I.S.P.E.S.L.
b.28
No signal from tachometer
b.29
Signal from tachometer not correct
b.30
T1–T2>∆T max
b.33
NTC3 short circuit
b.38
NTC3 interrupted
b.65
Awaiting fan start
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© MHG Heating Ltd Weather Compensation Curve An outside air sensor is required to activate the direct on boiler weather compensation function. The curve can be adjusted from its defaults to provide the comfort level the installation requires. The curve defaults are: Para
Default Setting
P4
60
P10
20
P11
-20
P12
25
Description Maximum Flow Temperature Achieved at Minimum Outside Air Temperature (P11) Minimum Flow Temperature Achieved at Maximum Outside Air Temperature (P12) Minimum Outside Air Temperature To Provide Maximum Boiler Flow Temperature (P4) Maximum Outside Air Temperature To Provide Minimum Boiler Flow Temperature (P10)
Worked Example: Para
Suggested
Description
Changes
P4
80
P10
25
P11
-1
P12
20
Maximum Flow Temperature Achieved at Minimum Outside Air Temperature (P11) Minimum Flow Temperature Achieved at Maximum Outside Air Temperature (P12) Minimum Outside Air Temperature To Provide Maximum Boiler Flow Temperature (P4) Maximum Outside Air Temperature To Provide Minimum Boiler Flow Temperature (P10)
The calculated flow temperature at an outside temperature of 0oC will be 77oC
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© MHG Heating Ltd Boost Function (Only Functioning when Weather Compensation is Active) The Boost Function is designed to bring the system to its maximum comfort level as quickly as possible. The calculated flow temperature is increased by 10°C for every time period set in Parameter P19 that the enable signal is applied. The calculation is reset if the enable signal is removed or the boiler reaches the maximum flow temperature as detailed in parameter P4. The default setting for P19 is 00
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© MHG Heating Ltd 0-10 Volt Control Adjustment If the boiler is to be controlled via a 0-10Volt signal an AM04 0-10 Volt adapter is required. The installation of the adapter is detailed earlier in the manual. Via Parameters 45 the 0-10Volt drive signal can be used to adjust the following: Setting
Function
04
Boiler Output via Fan Speed Adjustment
05
Boiler Flow Temperature
Boiler Output via Fan Speed Control On/Off Hysteresis:
Field Of Operation
Input Signal <0.5 volt = Boiler Off
Input Signal 1 to 1.8 volt = Boiler on at Minimum Operating Setting
Input Signal >1.0 volt = Boiler On
Input Signal 10 volt = Boiler on at Maximum Operating Setting (P22)
Boiler Output via Flow Temperature Control On/Off Hysteresis:
Field Of Operation
Input Signal <0.5 volt = Boiler Off
Input Signal 0.5 volt = Boiler on at Minimum Operating Setting
Input Signal >1.0 volt = Boiler On
Input Signal 9.5 volt = Boiler on at Maximum Operating Setting (P4)
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© MHG Heating Ltd Converting The Appliance To Burn LPG (G31) Unless specified at the time of ordering the appliance/s will be supplied ready to operate on a Natural Gas (G20) fuel supply. The appliances data badge will indicate the type of fuel gas the modules have been set to operate with. If the unit is required to operate on LPG the following conversion procedure must be undertaken. Isolate the appliance from the gas and electrical supplies. Discount the gas valve (VR8615) from the inlet gas supply being careful to retain the sealing washer. Remove the four bolts attaching the gas valve (VR8615) to the fan inlet manifold being careful to retain the sealing washer. Remove the Natural Gas 10.7mm Restrictor. Install the LPG 6.99mm Restrictor. Install the LPG gas valve (VR8625) in reverse order ensuring the correct location of the inlet and outlet sealing washers. Test for gas tightness. The appliance will now require commissioning.
Gas Type
ProCon MC 115
Natural Gas (G20)
10.7mm
LPG (G31)
6.99mm
High Fire
High Fire Fan
Low Fire
Low Fire Fan
C02/O2
Speed RPM
C02/O2
Speed RPM
Natural Gas (G20)
9.15 / 4.7
6300
8.90 / 5.2
1700
LPG Propane (G31)
10.30 / 5.2
5500*
10.10 / 5.5
1400*
LPG Butane (G30)
10.30 / 5.2
6300
10.10 / 5.5
1700
Gas Type
*The fan speed for Propane requires updating from the Natural Gas default
Parameter
Original Setting (NG G20)
Required Setting (LPG G31)
P22
63
55
P26
17
14 64
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© MHG Heating Ltd Commissioning The Appliance Pre-Commissioning Checks Prior to undertaking the commissioning of the unit please ensure that the system water has been cleansed and treated with a suitable inhibitor as detailed in Filling the System and System Water Quality. Prior to applying power to the appliance its circulation pump (b) should be bled and checked to ensure free rotation of the armature and the automatic air vent (a) should be opened and allowed to vent the heat exchanger and associated pipework. Better access to the pump can be achieved by removing the air duct from the fan inlet Venturi. Also ensure that the ignition electrodes spark gap is set to 4mm.
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© MHG Heating Ltd Combustion System Commissioning To ensure correct operation of the combustion system the gas valve must be set at Maximum and Minimum outputs. The commissioning mode can be activated regardless of the operating status of the heating and how water control system. If zone or mixing valves are installed within the system ensure that these are open to allow for complete circulation of the generated heat.
The High Fire commissioning mode is activated by pressing the MODE & + buttons simultaneously. The Low Fire commissioning mode is activated by pressing the MODE & - buttons simultaneously. To leave the commissioning mode press the RESET button or the + & - Button simultaneously. It is advisable to check the combustion figures on High and Low Fire prior to carrying out any adjustments. Adjusting the High Fire has a marked effect on the Low Fire figures. Where as adjusting the Low Fire has little effect on the High Fire figures. The High fire adjustment is carried out via red sheathed screw (4) (Make small adjustments 1/12 turn only.) The High Fire adjustment is a Gate type restrictor. Therefore turning the screw clockwise will close the Gate and thus restrict the quantity of gas passing through to the burner. The Low fire adjustment is carried out via the 4mm TORX head (2) (Under dust cap) The Low Fire adjustment is a diaphragm governor. Therefore turning the screw clockwise will increase the pressure on the diaphragm and thus increase the quantity of gas passing through to the burner. 66 MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email [email protected] Web www.mhgheating.co.uk 010315 Draft
© MHG Heating Ltd
Legend 1.
Gas inlet pressure
2.
Low fire adjuster(Governor type) Under dust cap*
3.
Valve outlet gas pressure
4.
High fir adjuster (gate type)* *(Make small adjustments only)
A flue gas analyser must be used to ensure that the correct combustion setting are achieved. This is undertaken by inserting the analyser’s probe in to plugged hole within the flue collector of the appliance or in the tapping in the flue immediately above the appliance if present. The combustion setting required for all ProCon appliances are as detailed in the following table. High Fire
High Fire Fan
Low Fire
Low Fire Fan
C02/O2
Speed RPM
C02/O2
Speed RPM
Natural Gas (G20)
9.15 / 4.7
6300
8.90 / 5.2
1700
LPG Propane (G31)
10.30 / 5.2
5500*
10.10 / 5.5
1400*
LPG Butane (G30)
10.30 / 5.2
6300
10.10 / 5.5
1700
Gas Type
*The fan speed for Propane requires updating from the Natural Gas default
Parameter
Original Setting (NG G20)
Required Setting (LPG G31)
P22
63
55
P26
17
14
67 MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email [email protected] Web www.mhgheating.co.uk 010315 Draft
© MHG Heating Ltd Routine Inspection and Servicing As with all Gas Appliances, we would highly recommended that a competent heating engineer services the ProCon MC, at least every 12 months. This is assuming a normal daily usage of 8 – 10 hours. If however the boiler is to be operated 24 hours a day, 7 days a week, we would recommend services every 6 months. If the Installer/Commissioning Engineer is unable to undertake the Routine Service Inspection, as detailed in Section 18.1, please contact the MHG Technical Department, who will be able to arrange the Routine Service Inspection to be undertaken.
Routine Service Inspection Before commencing any service/maintenance work, the following tasks must be undertaken. a) Ask the end user about any problems with the operation of the boiler unit and note their comments. b) Check the water pressure of the installation. c) Remove the boiler casing and visually inspect all pipe and water joints for signs of leakage. d) Inspect the top of the casing and the top of the heat exchangers for signs of water leakage or ingress. e) Run the unit in Commissioning Mode HIGH FIRE; with the use of a flue gas analyzer record the CO 2 level. f) Run the unit in Commissioning Mode LOW FIRE; with the use of a flue gas analyzer record the CO2 level. g) Listen to the sound of the combustion fan. Utilizing the appliances fascia review the units Operating Error Codes, and note the recorded codes onto the Service Report. h) Undertake a System Water Analysis to check the concentration level of the Water Treatment, and note the level onto the Service Report. i)
Check the flue route including the terminal position for conformity with prevailing regulations, and trim back any foliage that may be around the terminal.
j)
Check the plant room/compartment ventilation system for conformity with prevailing regulations.
k) Check the Pressure (Safety) Relief Valve size, rating and orientation, for conformity with prevailing regulations. The results of the Inspections undertaken above must be acted upon, and all discrepancies should be recorded on the Service Report and brought to the Client / End User’s attention. Undertake any maintenance, and if necessary any preventative maintenance, that’s required.
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© MHG Heating Ltd Routine Cleaning & Maintenance As part of the Routine Service Inspection, certain areas of the boiler need to the checked and cleaned as necessary. a)
Turn the boiler OFF at the ON/OFF switch and electrically isolate the boiler by removing the plug or fuse from the boiler supply.
b)
Turn off the gas at the boiler isolation tap, fitted by the installer, adjacent to the appliance.
c)
Remove the electrical connections, Gas valve balancing pipe and air inlet duct from the units fan assemble.
d)
Disconnect the earth lead, HT cap and Lead from the ignition electrodes.
e)
Loosen and disconnect the inlet gas supply form the gas valve. (Inspect and clean the inlet filter of the gas valve).
f)
Disassemble the burner by removing the six M6 nuts around the burner door, using a 10mm Spanner. Pull the burner forward and remove from the heat exchanger. Gently put to one side.
g)
Once access has been gained to the combustion chamber and lower heat exchanger, visually inspect the heat exchanger coils. It is usually only necessary to clean the lower section of the heat exchanger.
If server deposits are
found, the upper section of the heat exchanger should also be checked and cleaned, which may necessitate the removal of the heat exchanger from the boiler. If any coils appear to be significantly dis-coloured, then a blockage of either, scale, magnetite, or general system debris has occurred which will have allowed excessive overheating to have occurred within the coil. If dis-colouration has occurred, then specialist de-scaling of the heat exchanger will be required, however, stress cracking may have occurred, and the heat exchanger may become porous following the de-scale works. h)
If the heat exchanger has not suffered from dis-colouration, as ‘Item g’ above, then a Standard Service can be undertaken. Using a natural bristled brush ONLY, remove the worst of the mineral/debris build up. With the use of the dissolved ProCon Combustion Chamber Cleaning Granules, spray the solution onto the heat exchanger surface and leave for approximately 5 minutes. This will help to remove any stubborn mineral deposits and clear the condensate drain connections. Finally brush the heat exchanger whilst rinsing thoroughly with copious amounts of fresh water.
ProCon Combustion Chamber Cleaning
Granules are available from MHG Heating Ltd Spares Department. A STEEL OR PVC BRUSH MUST NOT BE USED TO CLEAN THE HEAT EXCHANGER. i)
Following the cleaning of the Heat Exchangers, the condensate syphon must be flushed to ensure that all mineral deposits/debris that has been washed from the heat exchanger surface is correctly removed. Open the syphon cleaning point cap at the base of the boiler, with a suitable receptacle directly below to collect the syphon contents. Safely dispose of the contents of the syphon. Replace the receptacle below the cleaning point and poor 2 litres of clean tap water into the heat exchanger, which will drain through the cleaning point.
Refit the cleaning point cap and poor one litre of clean tap water into the heat
exchanger to ensure the syphon is re-flooded. Check the cleaning point cap for leaks. j)
Visually check the burner surface for signs of damage and debris build-up. Remove any debris build up with compressed air. If excessive debris build-up is identified, the burner lance should be removed and the inner metal surface should be washed and cleaned. A BRUSH, OF ANY KIND, MUST NOT BE USED TO CLEAN THE BURNER SURFACE. If damage has occurred to the burner surface, the burner MUST be replaced.
69 MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email [email protected] Web www.mhgheating.co.uk 010315 Draft
© MHG Heating Ltd k)
To ensure that the rectification circuit operates correctly the resistance between the burner and burner door must be check with a multi-meter to ensure that it is less than 1 Ohm (<1 Ohm.)
l)
Clean with abrasive material and inspect the ignition electrode. Replace if necessary. Adjust the spark gap to 4mm.
m)
Check the combustion fan blades for debris build-up. Remove any debris with a soft bristle brush or preferably compressed air. DO NOT TOUCH OR SPIN THE FAN BLADES WITH YOUR FINGERS AS THIS COULD AFFECT THE BALANCING OF THE FAN BLADES.
n)
Re-fit the Burners, in the reverse order of dismantling, ensure that all electrical connections are correctly and securely connected.
o)
Inspect all water joints. Any joints found to be leaking MUST be replaced. It is also advisable when replacing water joints to also change any adjacent joints at the same time.
p)
Inspect all gas joints with a suitable leak detection method. Any joints found to be leaking MUST be replaced. It is also advisable when replacing gas joints to also change any adjacent joints at the same time.
q)
Via the tappings on the boiler connector adapter, elbow or straight a flue gas recirculation check must be undertaken when the boiler is operating on high and low fire modes.
r)
Drain and clean the condensate syphon assembly.
s)
If fitted inspect and clean the condensate neutralising tank, replenishing the neutralising granules as required. Granules available from MHG Heating Ltd Spares Department.
t)
With the use of a suitable Flue Gas Analyser, check and adjust the combustion settings, as detailed in the previous commissioning section.
u)
Inspect the general condition of the flue system, including the termination, repair as necessary or advise on any remedial action as required.
70 MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email [email protected] Web www.mhgheating.co.uk 010315 Draft
© MHG Heating Ltd User Information The ProCon’s display panel provides operational information and a means of adjusting the unit to provide the required level of heating and hot water generation. Off = **Frost Protection and anti-seize programs disabled** **Summer Mode = Hot Water Generation Only** **Winter Mode = Heating and Hot Water Generation**
Legend
Button
Function
COD
LED Display. Operating Temperature, Modes and Fault Codes
RESET
Resetting of an Operation Fault
MODE
Selections of an Operating Mode to Inspect or Amend
STEP
Scrolling of the Parameter List
STORE
Saving any Parameter Alterations
+
Positive Adjustment
-
Negative Adjustment
Following the powering up of the appliance a series of internal checks are undertaken. This can take a number of minutes. During this process the appliance will not respond to any requests for heat. “A” followed by a number will be displayed on the boilers LED display card.
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© MHG Heating Ltd Operating Modes The boiler display will provide operational data in all modes. Including a no demand state. The display is divided in four segments. The operational data will always be displayed in the first segment with a numerical code.
Status
Boiler operation
0
Standby; no heating or hot water required
1
Pre-ventilation / post-ventilation
2
Ignition
3
Burner operating in heating mode
4
Burner operating in hot water mode
5
Awaiting air pressure switch or rpm to start
6
Burner off as set point reached. Heating still required
7
Pump post-circulation after heating mode
8
Pump post-circulation after hot water mode
9
Burner blocked
A
Auto adjusting
H
Boiler in test mode, high fire
L
Boiler in test mode, low fire
72 MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email [email protected] Web www.mhgheating.co.uk 010315 Draft
© MHG Heating Ltd Cut-Out Codes If the boiler has malfunctioned an error/cut-out code will be displayed in the first, third and fourth segments. Status
Boiler Operation
b.08
Air pressure switch
b.18
Delivery temperature T1>95°C
b.19
Return temperature T2>95°C
b.24
T2-T1 > 10°C after 90 seconds
b.25
dT1 / dt > maximum gradient T1
b.26
Gas pressure switch or absence of water not closed / Thermostat for regulation I.S.P.E.S.L.
b.28
No signal from tachometer
b.29
Signal from tachometer not correct
b.30
T1–T2>∆T max
b.33
NTC3 short circuit
b.38
NTC3 interrupted
b.65
Awaiting fan start NTC3 = HWS Sensor
If the unit fails to operate and displays an error code please make a note of the code prior pressing the RESET button. If site support is required the noting of the error code will assist with the fault diagnosis and the provision of suitable replacement components if required. If the cause of the operational error has not been rectified the boiler will display a further error code following a period of up to 5 minutes during which time the unit is undergoing an internal diagnosis process.
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© MHG Heating Ltd Setting the Operating Temperatures The operation and temperature settings for both heating and hot water can be set via the control panel. (All alterations must be made from a Standby Menu / Default Display) Number that appears in
Field of
the first field of the
Description of parameter
display
Value set in
adjustment
factory
allowed
1.
Hot water temperature setting
From 20°C to
50°C
65°C
00 = Off (disabled) 2.
Hot
01 = On (enabled)
water
02 = Off + pump always on
/
00
/
01
03 = On + pump always on 00 = Off (disabled) 3.
01 = On (enabled)
Heating
02 = Off + pump always on 03 = On + pump always on
4.
Setting the heating water temperature
From 20°C to
60°C
85°C
The settings are made in the PARA menu. Press the MODE button once.
PARA
To adjust the HWS set temperature Press the STEP button until 1 appears in the display. Use the + or – buttons to alter the display to the required setting. (20c-65C) Press the STORE button to save the changes. Press the Mode Button once to return to the selection menu. Press the STEP button once to access the next parameter. Alternatively.
1. 50
Press the MODE button twice to return to the Standby Menu. To adjust the HWS operating mode Press the STEP button until 2 appears in the display. Use the + or – buttons to alter the display to the required setting. See table above for setting options. Press the STORE button to save the changes. Press the Mode Button once to return to the selection menu. Press the STEP button once to access the next parameter.
2. 00
Alternatively. Press the MODE button twice to return to the Standby Menu. To adjust the Heating operating mode Press the STEP button until 3 appears in the display. Use the + or – buttons to alter the display to the required setting. See table above for setting options. Press the STORE button to save the changes. Press the Mode Button once to return to the selection menu. Press the STEP button once to access the next parameter.
3. 01
Alternatively. Press the MODE button twice to return to the Standby Menu. To adjust the Heating set temperature Press the STEP button until 4 appears in the display. Use the + or – buttons to alter the display to the required setting. (20C-85C) Press the STORE button to save the changes. Press the Mode Button once to return to the selection menu. Press the STEP button once to access the next parameter. Alternatively.
4. 60
Press the MODE button twice to return to the Standby Menu.
74 MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email [email protected] Web www.mhgheating.co.uk 010315 Draft
© MHG Heating Ltd Operational Diagram
Legend Item
Description
MI
Boiler Flow
GAS
Gas Inlet
SC
Condensate Outlet
RI
System Return
1
Combustion Fan
2
Air Gas Mixing Venturi
3
Heat Exchanger
4
Premix Burner
5
Flow Sensor NTC 1
6
Return Sensor NTC 2
7
Gas Valve
8
Automatic Air Vent
9
Boiler Pump
10
Minimum System water Pressure Switch
11
Pressure Relief Valve
12
Control Panel
15
Outside Air Sensor
16
Condensate Trap
17
Pressure Gauge
18
Tundish
19
Flue Gas Analyser Test Point
20
Flue Gas Thermostat
75 MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email [email protected] Web www.mhgheating.co.uk 010315 Draft
© MHG Heating Ltd
Sensor Resistance Table
T(°C)
R(kΩ)
-15
76.02
-10
58.88
-5
45.95
0
36.13
5
26.60
10
22.80
15
18.30
20
14.77
25
12.00
30
9.804
35
8.054
40
6.652
T(°C)
R(kΩ)
45
5.522
50
4.607
55
3.862
60
3.252
65
2.751
70
2.337
75
1.993
80
1.707
85
1.467
90
1.266
95
1.096
100
0.9524
76 MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email [email protected] Web www.mhgheating.co.uk 010315 Draft
© MHG Heating Ltd Exploded Spares Diagram
77 MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email [email protected] Web www.mhgheating.co.uk 010315 Draft
© MHG Heating Ltd Exploded Spares Diagram
78 MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email [email protected] Web www.mhgheating.co.uk 010315 Draft
© MHG Heating Ltd Exploded Spares Diagram
79 MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email [email protected] Web www.mhgheating.co.uk 010315 Draft
© MHG Heating Ltd Notes
80 MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email [email protected] Web www.mhgheating.co.uk 010315 Draft
